Methods of assembling electrical components

ABSTRACT

A rotatable turntable having a plurality of workholders spaced about the periphery thereof is indexed to advance each of the workholders successively through each of a plurality of work stations positioned adjacent the periphery of the turntable to assemble electrical components. A first part positioned in one of the workholders has the leading end of an insulated wire extending from a supply of wire welded thereto, after which the first part is indexed to another work station without severing the wire extending from the first part to the supply. A portion of the wire extending to the first part in the workholder is severed from the supply and the new leading end of the wire is attached to the first part in the next succeeding workholder. The first part is rotated in the first workholder while tensioning the wire extending from and secured to the first part to wind the wire thereon as the workholder is advanced with the turntable. Facilities are provided for orienting the workholders prior to the winding of the wire on the first parts. Subsequently, a second part is assembled to the first part and, simultaneously, the insulation on a portion of the wire extending from the first part is stripped, whereafter the trailing portion of the wire is welded to a metal cap which is secured to the second part, the strength of the weld is tested, and the electrical component is advanced to a last work station, tested electrically, and then sorted.

United States Patent La Valle 1451 Sept. 12, 1972 [54] METHODS OFASSEMBLING ELECTRICAL COMPONENTS [72] Inventor: Thomas Alvin La Valle,Annapolis,

[73] Assignee: Western Electric Company, lncorporated, New York, N.Y.

[22] Filed: Aug. 13, 1971 [2l] Appl. No.: 171,439

Related U.S. Application Data [62] Division of Ser. No. 878,017, Nov.19, 1969,

Pat. No. 3,618,204.

[52] U.S. cl ..29/430, 29/203 D, 29/605 [51] lm. Cl. Bzsp 19/00, Hosk13/00, H01f7/06 [58] Field of Search ..29/430, 605, 624, 203 D,

203v DT, 29/203UDTs, 208 C, 20s R [56] References Cited UNITED STATESPATENTS 2,874,522 2/ 1959 McCabe ..29/430 X 3,473,213 10/ 1969 Brown..29/203 D 3,525,151 8/1970 Pellerin ..29/624 3 ,564,707 2/1971 Ensign..29/ 605 Primary Examiner-Thomas H. Eager Attorney-W. M. Kain et al.

[57] ABSTRACT A rotatable turntable having a plurality of workholdersspaced about the periphery thereof is indexed to advance each of theworkholders successively through each of a plurality of work stationspositioned adjacent the periphery of the turntable to assembleelectrical components. A first part positioned in one of the workholdershas the leading end of an insulated wire extending from a supply of wirewelded thereto, after which the first part is indexed to another workstation without severing the wire extendingfrom the first part to thesupply. A portion of the wire extending to the first part in theworkholder is severed from the supply and the new leading end of thewire s attached to the first part in the next succeeding workholder. Thefirst part is rotated in the first workholder while tensioning the wireextending from and secured to -the first part to wind the wire thereonas the workholder is advanced with the turntable. Facilities areprovided for orienting the workholders prior to the winding of the wireon the first parts. Subsequently, a second part is assembled to thefirst part and, simultaneously, the insulation on a portion of the wireextending from the first part is stripped, whereafter the trailingportion of the wire is welded to a metal cap which is secured to thesecond part, the strength of the weld is tested, and the electricalcomponent is advanced to a last work station, tested electrically, andthen sorted.

2 Claims, 21 Drawing Figures METHODS OF ASSEMBLING ELECTRICAL COMPONENTSCROSS-REFERENCE TO RELATED APPLICATION This is a division of applicationSer. No. 878,017, filed Nov. 19, 1969, now U.S. Pat. No. 3,618,204,issued Nov.9, 1971.

BACKGROUND oF THE INVENTION l. Field of the Invention This inventionrelates to methods of assembling electrical components and, moreparticularly, to methods of advancing successive ones of a mass of partson an indexable turntable through a plurality of work st ations toattach an insulated wirefrom a supply thereof to successive ones of theparts and for winding the wire on the associated successive ones of theparts. i

2. Description of the Prior Art In the manufacturing of electricalcomponents, first parts and second parts must be fabricated andassembled together. For example, in the manufacture of heat coils whichare used in central offices in incoming telephone lines to ground outoverload currents before these currents damage the equipment in thecentral office, a bared leading end of an insulated filamentary wiremust have a portion thereof welded to a sleeve of a pin and sleevesubassembly and then the wire must be wound around the pin and sleevesubassembly. The trailing end of the wire must be stripped of insulationand welded to a metal cap attached to a plastic shell which has beenpositioned over the pin and sleeve subassembly.'

ln the past, many of the operations related to the assembly of theseheat coils have been accomplished by hand. Needless to say, this hasbeen a time consuming and expensive task. Clearly, with the largequantities of metal cap, respectively. However, no facilities wereprovided in these apparatus for orienting at least a portion of thewinding facilities to insure uniform troubleheat coils which arerequired in buildingvand maintaining telephone systems, moresophisticated methods and apparatus are in order for the mass productionof heat coils.

To date, commercially available apparatus have been available whichperform some of the steps required for the more efficient assembly ofheat coils. Some of these apparatus include devices for feeding the pinand sleeve subassemblies successively and individually into workholdersarranged about the periphery of an indexable turntable. The pin andsleeve subassemblies are fabricated in the workholders and,subsequently, individual ones of a mass of plastic shells having a metalcap secured to one end thereof are fed into engagement with and securedto individual ones of the pin and sleeve subassemblies. Moreover, theseapparatus have also included devices for stripping-initially acontinuous insulated conductor wire from a supply thereof at spacedportions along the length thereof. The spaced portions coincide with thepoint of initial attachment of the wire to the sleeve of the pin andsleeve subassembly and to the point of subsequent attachment of thetrailing end of the wire to the cap on the plastic shell. Facilitieshave also been provided for winding the wire on the pin and sleevesubassembly as the pin and sleeve subassemblies are advanced through thework stations spaced about the periphery of the turntable. Weldingstations are provided in these apparatus for welding the leading and thetrailing ends of each length of wire to the sleeve of the pin and sleevesubassembly and to the free winding of convolutions of wire onassociated successive ones of the pin the sleeve subassemblies on anautomatic basis.

SUMMARY OF THE INVENTION It is an object of this invention to providenew and improved methods of assembling automatically electricalcomponents.

It is another object of this invention to provide methods of attachingan insulated wire from a supply to successive ones of a plurality ofparts and for winding successive sections of the wire to associatedsuccessive ones of the parts.

A method of attaching insulated wire from a supply thereof to a partheld in a rotatably mounted workholder having a toothed wheel attachedthereto and for winding the wire on the part as the toothed wheel isadvanced alongI and in engagement with a rack, which comprises the stepsof removing the insulation from a leading portion of the wire, advancingthe workholder into engagement with an orienting device to rotate thetoothed wheel to orient the toothed wheel so that the toothed wheel ispositioned to engage subsequently with the rack, causing relativemovement between the wire and the part to engage the leading portion ofthe wire with the part of the wire running to the supply thereof,securing the bared leading portion of the wire to the part, advancingthe workholder to engage the toothed wheel with the rack, and furtheradvancing the workholder to roll the toothed wheel along the rack tomove rotatably the workholder while simultaneously tensioning the wireto wind the wire on the part.

BRIEF DESCRIPTION OF THE DRAWINGS Other objects and features of thepresent invention will be more readily understood from the followingdetailed description of specific embodiments thereof when read inconjunction with the appended drawings, in which:

FIG. 1 is a perspective view ofa heat coil showing a pin and sleevesubassembly which is assembled by the principles of the methods of thisinvention;

FIG. 2 is a plan view of an apparatus which is used to carry out themethods of this invention which includes a rotatably mounted circularturntable having a plurality of workholders arrayed about thecircumferential edge thereof for advancing each of the workholderssuccessively through each of a plurality of work stations for assemblinga pin andsleeve subassembly with a shell and cap subassembly to assemblea heat coil;

FIGS. 3 through 9 are a series of enlarged elevational views of the heatcoil in various stages of assembly beginning with the pin and sleevesubassembly which is advanced through the work stations to have one endof a conductor wire welded thereto, then to have a shell and capsubassembly placed thereover and another end of the conductor wirewelded to the cap of the shell and cap subassembly;

FIG. 10 is an enlarged sectional view of a pin and sleeve subassemblyfeed device of the apparatus of FIG. 2 taken along line 10-10 thereofwith portions broken away for purposes of clarity;

pushing the pin and sleeve subassemblies over the workholder inregistration with that station;

FIG. 12 is an enlarged sectional view of a conductor wire feedingstation of the apparatus of FIG. 2 taken along line 12-12 thereofillustrating the conductor wire being payed out from a supply spool andadvanced through a stripping device wherein predetermined portions ofthe-conductor wire are bared of the insulation;

FIG. 13 is an enlarged sectional view of a welding device of theapparatus ofFIG. 2 taken along line 13- 13 thereof;

FIG. 13A is an enlarged perspective view of a portion ofa weldingelectrode of the welding device of FIG. 13;

FIG. 14 is an enlarged sectional view of the welding station of FIG. 13taken along line 14-14 thereof which illustrates a pinion orienterlocated on the underside of the turntable at the welding station fororienting the pinion attached to a shaft extending from below theworkholder and which engages subsequently a rack for turning theworkholder and which engages subseq uently a rack for turning theworkholder and the pinv and sleeve subassembly held therein tofacilitate winding the wire on the sleeve of the pin and sleevesubassembly;

FIG. 15 is an enlarged sectional view ofa cutting station oftheapparatus of FIG. 2 taken along line 15-15 thereof whichillustrates adevice for severing the wire extending from the weld thereof to thesleeve of the pin and sleeve subassembly in a leading workholder to thesupply spool and with a new leading end of the conductor wire beingwelded to the sleeve of the succeeding one of the pin and sleevesubassemblies;

FIG. 16 is an enlarged sectional view of a swaging station of theapparatus of FIG. 2 taken along line I6- 16 thereof which illustrates adevice for swaging the upper peripheral rim of the sleeve of each of thepin and sleeve subassemblies to slope the rim inwardly;

FIG. 17 is an enlarged plan view of one of the workholders which isarrayed about the circumferential peripheral edge of the turntable andhaving a pivotally mounted arm for distributing the wire around thesleeve of a pin and sleeve subassembly as the arm is moved pivotally bya cam follower which rides on a contoured can surface on a platform;

FIG. 18 is a detailed plan view showing the engagement of the pinion onthe shaft extending from the chuck of each of the workholders with therack on the underside of the turntable to rotate the chuck and the pinand sleeve subassembly held therewithin to wind the convolutions of wireon the sleeve as the distributor arm is moved pivotally;

FIG. 19 is an enlarged elevational view of one of the workholders of theapparatus of FIG. 2 taken along line 19-19 thereof and illustrating theupward movement of the distributor arm on the workholder to push aportion of the wire extending from the pin and sleeve subassembly inapproximate engagement with the cap of the shell and cap subassemblyassembled to the pin and the sleeve subassembly which is positioned inthe workholder to facilitate subsequent welding of the wire to the cap;and

4 FIG. 20 is a plan view of the turntable and the platform shown in FIG.2 and illustrating various limit switches which are positioned on theturntable and the platform for controlling automatically the operationof the assembly apparatus.

DETAILED DESCRIPTION i Referring now to FIG. 1, there is shown a heatcoil assembly, designated generally by the numeral 4l, which is to beassembled by the methods of this invention. The heat coil assembly 41includes a pin and sleeve subassembly 42 and a shell and cap subassembly 43. As can be seen in FIG. 3, the pin and sleeve subassembly 42includes a pin 44 having a knurled end 46 and a pointed end 47. The pin44 is soldered with a low melting temperature alloy, such as a bismuthmixture, in a sleeve 48 with the pointed end 47 protruding slightly fromone end of the sleeve. The knurled end 46 extends some distance from theother end of the sleeve 48. Each of a mass of the pin and sleevesubassemblies 42-42 is assembled with one of a mass of the shell and capsubassemblies 43-43 so that the knurled end 46 is received in a recessin a closed end 49 (see FIG. 8) ofa housing or shell 5l.

The shell 51 is cylindrically shaped, having an open end 52 at one endthereof, and may be constructed of any suitable material, such as aplastic. The shell S1 is also formed with a slot 53 parallel with thelongitudinal axis of the shell. The other closed end 49 of the plastichousing 51 has a beveled portion 54 which connects the cylindricalportion of the housing with the closed end. Moreover, a solder-platedbrass cap 56 is received over the closed end 49 and is attached to theplastic shell 51 by protrusions 57 in the cap being received inindentations in the shell 51 (s ee FIG. l).

Prior to the assembly of the pin and sleeve subas` sembly 42 with theshell and cap subassembly 43, one end of an insulated conductor wire S9extending from a supply has the insulation removed therefrom and iswelded to the sleeve 48 of the pin and sleeve subassembly (see FIG. 4).Then a portion of the wire 59 extending to the pin and sleevesubassembly 42 is severed (see FIG. 5) from the supply and the newleading end of the wire is attached to the pin and sleeve subassembly inthe next succeeding workholder while maintaining the trailing part ofthe wire taut, and an upper rim of the sleeve 48 is swaged (see FIG. 6).The pin and sleeve subassembly and the workholder are rotated and aninsulated portion of the conductor wire 59 is wound around the sleeve 48(see FIG. 7). Subsequently, the insulation is removed from anotherportion of the length of wire and one of the pin and sleevesubassemblies 42-42 is assembled with the shell and cap subassembly 43with the knurled end 46 received in the closed end 49 and with the otherunwound part of the conductor wire extending through the slot 53 in theshell 51 (see FIG. 7). Then, the portion of the conductor wire 59 iswelded to the cap S6 (see FIG. 8), after which the strength of the weldof the wire to the cap is tested. Then the heat coil assembly 4l ismoved to a final station where an electrical characteristic of the heatcoil assembly is determined and then the heat coil assembly is sorted inaccordance with the test characteristic.

GENERAL OVER-ALL DESCRIPTION OF THE APPARATUS An apparatus, designatedgenerally by the numeral 60 (see FIG. 2), for carrying out theprinciples of the methods of this invention includes a turntable 61which is mounted rotatably on a b ase 62 (see FIG. 10) and which has aplurality of work stations arrayed about the periphery thereof.Moreover, the turntable 61v also has a plurality of workholders 63-63attached to the turntable around the periphery thereof. At a firststation (station No. l, FIG. 2), a feeding device, designated, generallyby the numeral 100, (see FIG. feeds successive ones of a mass of the pinand sleeve subassemblies 42-42 (see FIG. 3) into successive onesof theAworkholders 63-63. Then a leading one of the workholders 63-63 63 ismoved with the turntable 61 to a second workstation (station No. 2, FIG.2) where a stripping blade 141 (see FIG. 12) strips a leading end oftheinsulated wire 59 and a welding device 150 (see FIG. 13) welds thebared leading end to the sleeve 48 (see FIG. 4) of the pin and sleevesubassembly 42. The conductor wire 59 may, for example,

'havea coppermickel-zinc composition. As the turntable 61 ismoved'rotatably into a third work station (station No. 3, FIG. 2), thewire 59 extends from the pin and sleeve subassembly 42 to a supply 64 ofthe wire. A't the third work station a cutting device, designatedgenerally by the numeral 160, (see FIG. l5), severs a length of the wire59 extending to the pin and sleeve subassembly 42 (see FIG. 5) in theworkholder 63 from the supply 64 with the new leading end of the wire 59attached to the sleeve 48 of the pin and sleeve subassembly 42 in thenext succeeding workholder 63. The workholder 63 is advanced to a fourthwork station (station No. 4, FIG. 2) where a swaging device, designatedgenerally by the numeral 1,90 (see FIG. 16), turns an upper rim of thesleeve 48 inwardly (see FIG. 6). After the rim of the sleeve 48 has beenswaged, the workholder is indexed through a fifth work station and thepin and sleeve subassembly 42 is rotated to wind the length of wire 59on the sleeve 48 (see FIG. 7) while tensioning the length of wireextending from and secured to the pin and sleeve subassembly 42. As thewire 59 is wound on the sleeve 48, the workholder 63 is advanced withthe turntable 61 to the sixth work station (station No. 6, FIG. 2) wherea stripping device 200 (see FIG. 2) removes the insulation from aportion of the wire extending from the pin and sleeve subassembly 42,(see FIG. 7), and where a feeding device, designated generally by thenumeral 210 (see FIG. 2), places a plastic shell 51 over the knurled end46 of the pin and sleeve subassembly 42 (see FIG. 8). Then the heat coilassembly 41 is moved to a seventh work station (station No. 7, FIG. 2)whereat a welding device, designated generally by the numeral 240, (seeFIG. 2), welds the portion of the wire 59 to the cap 56 (see FIG. 9)whereafter the strength of the weld to the cap is tested. Finally, theturntable 6 1 is indexed to position the heat coil assembly 41 at afinal work station (station No. 8, FIG. 2) 'where a testing and sortingdevice, designated generally by the numeral 260, determines anelectrical test characteristic of the heat coil assembly, after whichthe heat coil assembly is ejected therefrom and sorted in accordancewith the test characteristic.

CoNvEYoR Referring now to FIG. 2, there is shown a conveyor, designatedgenerally by the numeral 65, which includes the turntable 6l. Theturntable 6l is secured to a shaft 66 and is moved rotatably with theshaft intermittently and successively in a clockwise direction, asviewed -in FIG. 2, to index the turntable through each of a plurality ofwork stations by a continuouslyoperated drive motor 67 (see FIG. 33).The turntable 61 is mounted on the shaft 66 so that the turntable isspaced from the base 62 (see FIG. 10). Moreover, a stationary, circulartop worktool platfonn 68 is mounted on the base 62 and is concentricwith the turntable 6l (see also FIG. 13). However, the circular topplatform 68 has a diameter somewhat smaller than the diameter of theturntable 61. In this way, a plurality of the workholders 63-63 may bemounted on and individually attached to the turntable 61 and arrayedabout the vperiphery thereof. Then, at each of the plurality of workstations, a plurality of work devices which are used to assemble theheat coil assemblies 41-41 may be attached to the circular top platform68 and to the base plate 62, and may cooperate to perform work functionson the workpiece in the workholders which are positioned on theturntable 61 in the space therebetween.

The top of the platform 68 has an annular cam surface 69 (see FIGS. 2and 13) concentric with the platform and adjacent the peripheral edge ofthe platform. The annular cam surface 69 has a height (h) (see FIG. 13)which varies along the circumference thereof to present a contoured orcam surface which is used in the winding operation of the wire S9 todistribute the wire on the pin and sleeve subassembly 42 and which willbe hereinafter described in detail.

Referring now to FIGS. -2 and 17, it can be seen that each of theworkholders 63-63 includes a base plate 71 having a block 72 attachedthereto at one end. The block 72 has a longitudinal channel 73 formedtherethrough for receiving one end of a distributor arm 74. Thedistributor arm 74 is pivotally mounted at one end thereof to the block72 by a pin 76 with the other end of the distributor arm extending fromthe channel 73 in a direction opposite to the clockwise rotary movementof the turntable 61.

The distributor arm 74 is assembled with a protruding portion 77 whichextends radially inwardly from the distributor arm toward the topcircular platform 68. A cam follower 78 is mounted rotatably on theprotruding portion 77 and engages the annular cam surface 69 of the topcircular platform 68. In this way, the cam follower 78 vsupports theunpinned other end of the distributor arm 74 and, as the turntable 61 ismoved rotatably about the stationary platform 68, the cam follower rideson the cam surface 69 to move pivotally the distributor arm 74 inaccordance with the configuration of the cam surface.

Moreover, the unpinned other end of the distributor arm 76 is equippedwith a tensioning device 81 (see FIG. 24) for receiving and tensioningthe wire 59. The tensioning device 81 includes a stud 82- having athreading groove in which the wire 59 is received with the stud 82positioned between the distributor arm 74 and an overlying bracket 83. Aspring mounted screw 84 extends through the bracket -83 and the stud 82and into the distributor arm 74 in order to mount the stud and to adjustthe compressive force between the stud 82 and a boss 8S of thedistributor arm. The tightening of the screw 84 increases the clampingeffect of the stud 82 on the wire 59 in the groove to tension the wire.

Each of the workholders 63-63 includes a guide 88 having a V-shapedopening 89 and mounted on a leading end of the block 72 (see FIG. 17).As can best be seen in FIG. 2, the stud 82, a chuck 86 and the guide 88are arranged on the workholder 63 so that the length of the wire 59strung between the V-shaped opening 89 and engaging the stud 82 issubstantially linear and engages the top portion of the circumferentialsurface of the sleeve 48 of the pin and sleeve subassembly 42 heldknurled end 46 extending upwardly. The jaws 90-90 are attached to ashaft 91 which extends downwardly through an opening in the turntable 61and which is spring biased in an upward direction. In this way, the jaws90-90 are normally biased upwardly to cam against the wall of theopening in the housing 87 of the chuck 86 to maintain the jaws in aclosed position. As the shaft 91 is moveddownwardly, the jaws 90-90 aredrawn downwardly and are cammed against the wall of the housing 87 toopen the jaws to permit insertion ofa pin and sleeve subassembly 42.-

The chuck 86 of the workholder 63 is also secured to the shaft 91 (seeFIGS. 10 and 29) which is mounted rotatably through the base plate 71and the turntable 61 in order to move rotatably the pin and sleevesubassembly 42 held on the chuck to wind the wire 59 on the sleeve 48.The shaft 91 has a pinion or toothed wheel 92 formed on the lower endthereof and has a collar 93 attached thereto just below thev lower endof the pinion 92. The pinion 92 is designed to mesh with a rack 94 (seeFIG. 18) mounted to the base 62 of the apparatus 60. As the turntable 61is indexed, the pinion 92 engages with the rack 94 to turn the shaft 91and rotate the chuck 86 and the pin and sleeve subassembly 42 which isheld between the jaws 90-90 of the chuck. In order to distribute thewirev59 vertically around the sleeve 48, the cam follower 78 of thedistributor arm 74 rides on the contour of the annular cam surface 69(see FIG. 17) to-move pivotally the distributor arm about the pin 76 todistribute the wire on the pin and sleeve subassembly 42 which isrotated with the chuck 86 by the cooperation between the pinion 92 andthe rack 94.

PIN AND SLEEVE SUBASSEMBLY FEEDING STATION Referring now to FIGS. 2, land 11, there is shown the pin and sleeve subassembly feeding device 100for feeding successive ones of a mass of the pin and sleevesubassemblies 42-42 into successive ones of the chucks 86-86 of theworkholders 63-63 which are spaced around the periphery of the turntable61. The pin and sleeve subassembly feeding device 100 includes a frame101 which is mounted on the base 62 of the apparatus 60 and alsoincludes any commercially available vibratory bowl feeder 102 which maybe adapted for use in the apparatus 60. The vibratory bowl feeder 102 isoperated to move the pin and sleeve subassemblies 42-42 from within thebowl along a ledge 103 and to advance the pin and sleeve subassembliesto a feed opening 104 formed in the ledge. As can be seen in FIG. 1 l,the feed opening 104 is adapted to receive a plurality of the pin andsleeve subassemblies 42-42.

The opening 104 overlies a reciprocally movable slide 106 which is movedradially outward from the turntable 61 toward the bowl feeder 102 sothat a receiving slot 107 in the slide receives the leading one of thepin and sleeve subassemblies 42-42 which has been advanced along theledgel03 and into the opening by the vibratory forces imparted the bowlfeeder. Then, the slide 106 is moved radially inward of the turntable 6laway from the bowl feeder 102 so that a solid portion 108 of the slidenow underlies the opening 104 and supports the remaining pin and sleevesubassemblies 42-42 in the opening. Moreover, the slide 106 is separatedphysically from the bowl feeder 102 so that the vibrations of the bowlfeeder are not imparted to the slide, which vibrations may unduly effectthe operation of the slide in feeding the pin and sleeve subassemblies42-42 to the workholder 63. After the slide 106 has received a leadingone of the pin and sleeve subassemblies 42-42 in the receiving slot 107and is -moved away from the bowl feeder 102, the receiving slot ispositioned over a pin 109 (see FIG. 11).

The pin 109 is used to orient the pin and sleeve subassemblies 42-42 forsubsequent movement into one of the chucks 8686 on one of theworkholders 63- 63 in registration with the feeding device 100. The pin109 is mounted transversely of the receiving slot 107 so that as each ofthe pin and sleeve subassemblies 42-42 is advanced by the slide 106 awayfrom the opening 104, the pin and sleeve subassemblies are moved in`- Adividually over and spaced kabove the pin, whereupon the pin and sleevesubassemblies drop vertically by gravity and come to rest on the pin.

The pin 109 is positioned beneath the right hand location of thereceiving slot 107, as viewed in FIG. 1l, so that regardless of thelongitudinal orientation of the pin and sleeve subassembly 42 within thereceiving slot, the pin and sleeve subassembly pivots about the pinsothat the pointed end 47 of the pin 44 is always oriented downwardly.Because of the construction of the pin and sleeve subassembly 42, thecenter of gravity is somewhere within the sleeve section 48. If the pinand sleeve subassembly 42 is fed with the pointed end 47 forward (asrelated to line of advancement along the ledge 103 of the bowl feeder102), the pin and sleeve subassembly cornes to rest on the pin 109 sothat the heavier sleeve 48 drops vertically downward first through apassage 111 and then into and through a chute 112, into a funnel 113 andinto a nest 1 14 formed in a second slide 116 (see FIGS. l0 and 11).

The second slide 116 is reciprocally movable by an air cylinder 117 (seeFIG. l0) so that as each of the successive ones of the pin and sleevesubassemblies 42-42 is received in the nest 114 in the second slide, theslide is moved by the air cylinder radially inward toward the turntable61 to position successively each of the pin and sleeve subassembliesover one of the chucks 86-86 of the workholders 63-63 currently inposition under the feeding device 100. Moreover, the nest 114 in theslide 116 is formed between a pair of opposed resilient fingers 118-118(see FIG. 11) which are biased inwardly toward each other by a pair ofopposed adjustably settable lugs 1 19 to clamp one of the pin and sleevesubassemblies 42-42 therebetween.

As can best be seen in FIGS. 10 and 11, the slide 116 is formed with oneend having tapered camming surfaces 115-115 which are used to controlthe escapement of the pin andfsleeve subassemblies 42-42 from the slide106 into the opening 111. Normally, the slide 106 is biased to theright, as viewed in FIG. 11, by a pivotally mounted rod 105 which hasone end protruding into an opening in the slide and which has the otherend urged in a clockwise direction, as viewed in FIG. 11, and intoengagement with one of the camming surfaces 11S-115 by a compressionspring 110. When the slide 116 is moved to position the pin and sleevesubassembly 42 held in the nest 114 thereof over one of the chucks86-86, one of the camming surfaces 115-115 is cammed against the lowerfollower end of the rod 105 to move pivotally the rod in acounterclockwse direction, as viewed in FIG. l1, to move the slide 106to the left to align the receiving slot 107 with the opening 104. Thealignment of the receiving slot 107 with the opening 104 permits thelowermost one of the pin and sleeve subassemblies 42-42 to drop into thereceiving slot with the remaining pin and sleeve subassemblies supportedon the pin and sleeve subassembly in the receiving slot. Then, when theslide 116 is moved retractably away from the chuck 86, the follower endof the rod 105 rides along one of the tapered camming surfaces 11S-115to permit the spring 1 10 to urge the rod in a clockwise direction. Asthe rod 105 is moved in a clockwise direction, the slide 106 is advancedto the right, as viewed in FIG. 11, to align the receiving slot 107 withthe opening 111 and to allow the pin and sleeve subassembly to dropdownwardlyinto engagement with the pin 109 and then into the chute 112.

As the slide 116 is moved over the chuck 86 of the workholder 71,currently positioned in registration with the feeding device 100, an airoperated plunger 121 is moved downwardly by an air cylinder 122, actingthrough a rod 123 slidably secured in a sleeve 124. The plunger 121imparts a pushing force to the pin and sleeve subassembly 42 andthereupon moves the fingers 118-118 away from one another as the plungercontinues to move downwardly and push the pin and sleeve subassemblythrough the nest 114 in the slide 116 and into the chuck 86 with theknurled end 46 of the pin 44 oriented upwardly (see FIG. 3).Simultaenously therewith, an air cylinder 126 is actuated to move apiston rod 127 and a block 128 downwardly, as viewed in FIG. 10, toimpart a pulling force through a plate 129 against the collar 93 to movethe shaft 91 downwardly. As the shaft 91 is moved downwardly, the jaws90-90 in the chuck 86 are opened to permit the pin and sleevesubassembly 42 to be received in the opening therebetween.

WIRE FEEDING AND WELDING STATION AND PINION ORIENTER The pin and sleevesubassembly 42 in a leading one of the workholders 63-63 is indexed intoa second work station of the apparatus 60 whereat a wire feeding and awelding device, designated generally bythe numerals 130 and 150,respectively, (see FIG. 2), removes the insulation from a leading end ofan insulated wire 59 and then welds the leading bared end to a topcircumferential portion of the sleeve 48 of the pin and sleevesubassembly.

Referring now to FIG. l2, there is shown the wire feeding and strippingdevice 130 at the second work station which includes a spool 131 of thefine gauge, e.g., 0.007l inch insulated wire 59. The spool 131 of wire59 is mounted for rotation on a stanchion 132 and is payed out so thatthe convolutions of wire are moved over one of the flanges of the spool.The insulated wire 59 is advanced through a spring-loaded guide block133 having a pair of plates 134-134, each of which has a groove 136formed therebetween for receiving the wire. The wire 59 is then advancedunder a pair of spaced hold-down bars 137-137. The hold down bars137-137 are attached to and extend from a vertical plate 138 which ismounted on the base plate,62 of the apparatus 60.

In order to strip spaced portions of the continuous insulated wire 59for subsequent welding of the wire to the sleeve 48 of each of the pinand sleeve subassemblies 42-42, a stripping blade 141 is provided. Thestripping blade 141 has a tapered edge with a U-shaped groove 142 formedtherein (see an identical blade 201, FIG. 21) to facilitate thereception of the wire 59. Moreover, the blade 141 is mounted on a rod143 which extends from a cylinder 144. The rod 143 has a cam follower145 `extending externally therefrom for following a cam opening 146 in aplate 139 attached to the vertical plate 138. The cylinder 144 has` oneend thereof pivotally mounted on a pin 147 supported in a bearing 148.In this way, the stripping blade 141 is mounted for vertical movement aswell as for horizontal movement.

As the wire 59 is advanced under the hold-down bars 137-137, thestripping blade 141 is actuated to move the blade upwardly and intoengagement with the insulated wire in the groove 136. Then, thestripping blade 141 is moved in the direction of advancement of the wire59 to strip a predetermined portion L (see FIGS. 4 and 12) from thewire. The wire 59 is then advanced continuously around a guide sheave149 which is rotatably mounted on a mounting bracket 135 attached to thebase 62 of the apparatus 60. The sheave 149 is positioned so that thewire 59 is pulled over the sheave and then through the groove betweenthe stud 82 and the distributor arm 74 (see FIG. 2) and then through theguide 88.

The vpredetermined length of bared wire L is spaced along the continuouslength of the wire 59 so that, as each of the chucks 86 on theworkholders 63- 63 is advanced into registration with the welding device150, one of the predetermined lengths L of bared wire is in engagementwith the top portion of the sleeve 48 of the pin and sleeve subassembly42 held in the workholder 63 currently in registration with the weldingdevice (see FIG. 4).

The welding device 150 is disposed in a clockwise direction from theguide sheave 149, as viewed in FIG. 1, and includes an anvil electrode151 and a welding electrode 152 which are spaced apart and which aremovable into engagement with the pin and sleeve subassembly 42 and withthe bared exposed portion L of the wire 59. As the electrodes 151 and152 engage the sleeve 48 and press the bared portion L of the wire 59against the sleeve 48, the welding device is operated to secure thebared portion to the sleeve 48.

As can best be seen in FIGS. 2 and 13, the welding electrode 152 ismounted on a carriage 153 which is slidably mounted in a housing 154 onthe base 62. The carriage 153 is moved slidably inward toward theturntable 61 by an air cylinder 155 to engage the welding electrode 152with the bared length L of the wire 59. The carriage 153 also has abracket 156 extending rearwardly therefrom along a radial line from thecenter of the turntable 61 for actuating a limit switch 322 and a limitswitch 304 which are used in controlling the operation of the apparatus60.

The welding electrode 152 is formed to facilitate engaging the wire 59between the welding electrode and the sleeve and to align vertically thewire on the sleeve 48. In order to accomplish these functions, thewelding electrode 152 has a thickness, measured along a vertical axis,as viewed in FIG. 13, slightly less than twice the thickness of the wire59. Moreover, the end of the welding electrode is formed with a concavesurface 160 for receiving the sleeve 48 of the pin and sleevesubassembly 42. The concave surface 160 has a pair of aligned slots165-165 extending transversely of the concave surface thereof. As thewelding electrode 152 is moved radially inward of the turntable 61, thewire 59 is received in the spaced slots'165-165 and moved intoengagement with the sleeve 48 and the concave surface 160.

Referring again to FIG. 13, it can be seen that the anvil electrode 151is attached to a carriage 157 having a rod 158 which is mounted slidablyin a pair of spaced bearings 159-159 that are supported on the platform68. One end of the rod 158 has a vertically upstanding actuator plate161 for actuating either of a pair of spaced limit switches 321 and 302(see also FIG. 32)

for controlling the operation of the apparatus 60. The l limit switches321 and 302 are attached to a mounting plate 162 which is secured to theplatform 68. In order to move the anvil electrode 151 radially of theturntable 61 and slidably into engagement with the sleeve 48 of the pinand sleeve subassembly 42 in registration with the welding device 150,an air cylinder 163 has a piston rod 164 attached to the carriage 157.

Moreover, the second work station which includes the wire feeding andstripping device 130 and the welding device 150 also includes a pinionorienter 166 (see FIG. 14). The pinion orienter 166 is mounted on thebase plate 62 of the apparatus 60 in alignment with the welding device150. lt has been noted hereinbefore that each ofthe chucks 86-86 has ashaft 91 depending downwardly therefrom with a pinion 92 and a collar 93secured to a lower end thereof. In order for the gear teeth 96-96 of thepinion 92 to engage correctly with the rack 94 at a subsequent stationin order to rotate the chuck 86 and the pin and sleeve subassembly 42held therein, it is necessary that the shaft 91 be oriented so that aleading one 96 of the gear teeth 96- 96 of the pinion or toothed wheelwill correctly engage the rack teeth of the rack 94. Should the pinion92 be oriented incorrectly, the gear teeth 96--96 may jam against therack 94 as the turntable 61 is indexed to engage the pinion with therack.

As can best be seen in FIG. 14, the pinion orienter 166 includes apivotally mounted lever arm 167 having a bossed end 168. Moreover, thelever arm 167 is normally biased in a clockwise direction, as viewed inFIG. 14, by a spring 168 into engagement with an adjustably settablestud bolt 169. As the turntable 61 is moved indexably to position one ofthe workholders 63-63 in registration with the welding device then,should the pinion 92 associated with that particular workholder 63 beoriented properly, the gear teeth 96-96 on the pinion 92 are spaced andsimply moved slidably along the surface of the bossed end 168 (see FIG.14). However, should one of the teeth 96-96 of the pinion 92, which isfarthest from the center of the turntable 61, be oriented in a directionalong the radius of the turntable (see tooth 96a of the pinion 92 shownin broken lines, FIG. 14), then the tooth 96a engages the edge of thebossed end 168 to rotate slightly the pinion, the shaft 91 and the chuck86 in a counterclockwise direction, as viewed in FIG. 14, until the nextadjacent tooth (tooth 96h, FIG. 14) slides along the surface of thebossed end. The orientation of the pinion 92 is accomplished just priorto the welding of the wire 59 to the sleeve 48.

SEVERING STATION With a bared portion of the wire 59 now welded to thesleeve 48 of the pin and sleeve subassembly 42 in the leading one of theworkholders 63-63, the turntable 61 is indexed rotatably to position thechuck 86 of the leading one of the workholders in registration with asevering device, designated generally by the numeral 170, (see FIG. 1S)at a third work station. At the third work station, the sleeve 48 of thepin and sleeve subassembly 42 is positioned between a pair of opposed,spaced cutting blades 171-171 of the severing device 170. One of thecutting blades 171-171 is supported from a frame 172 which is mounted ontop of the circular top platform 68. The other one of the cutting blades171-171 is mounted on a reciprocally movable carriage block 173 which ismounted on a stand 174 that is attached to the base 62. The carriageblock 173 is rigidly attached to a rod 176 which is slidably mounted inbearing plates 177-177 which are attached to the top of the stand 174.An air cylinder 178 is mounted on the stand 174 between the bearingplates 177- 177 and having a piston rod 179 extending therefrom andattached to the carriage 173.

Similarly, the one cutting blade 171 is mounted on a carriage block 181that i's attached to a forward end of a pair of spaced rods 182-182which are slidably mounted in a pair of spaced plates 183-183 of theframe 172. Moreover, the block 181 is attached to one end of a pivotallymounted arm 184. The arm 184 is pivotally mounted at a center pointthereof between a pair of spaced ears 186-186 which project from anupstanding portion of one of the spaced plates 174- 174. The other endof the pivot arm 184 is pinned to an actuator rod 187. The actuator arm187 extends over and above one of the workholders 63-63 positionedtherebelow on the turntable 61 and has an end thereof pinned to anupstanding portion of the carriage block 173.

As the air cylinder 178 is actuated, the piston rod 179 is movedinwardly toward the turntable 61 to move the carriage block 173 and thecutting blade 171 attached thereto inwardly toward the chuck 86. As theb lock 173 is moved toward the turntable 61, the actuator rod 187 ismoved toward the center ofthe turntable 61 to move pivotally the arm 184in a clockwise direction, as viewed in FIG. 15, to move the lower end ofthe arm to the left and toward the chuck 86. As the lower end of the arm184 is moved toward the workholder 63, the carriage block 181 andcutting blade 171 mounted thereon are moved inwardly toward the lpin andsleeve subassembly 42 in the workholder 63 currently in position in'thesevering station. The cutting blades 171-,171 cooperate to sever thebared end of the wire 59 on the leading (or clockwise) side of the pinthe sleeve subassembly 42 currently in position in the severing station.After the wire 59 hasbeen severed, the workholder 63currently in thesevering station has a pin and sleeve subassembly 42 held in the chuck86 thereat with the bared end of the wire 59 welded to the sleeve48 ofthe pin and sleeve subassembly and with the wire extendingcounterclockwise thereof past the pin and sleeve subassembly in thechuck currently in the wire feeding and welding station with the wire 59continuing thereon to the supply spool 131.

As should be apparent, if the workholder 63, currently in the severingstation, is the leading one of the workholders, then a leading bared endof the wire 59 is welded to the sleeve 48 of the pin and sleevesubassembly 42. In that case, it is not until the leading one of theworkholders 63-63 is indexed to a fourth work station and a nextsuccessive one of the workholders is indexed into the severing stationthat severance of the wire 59 occurs. Then, when the wire 59 is severed,a length of the wire extends from the pin and sleeve subassembly 42 inthe leading one of the workholders 63- 63 with the trailing end thereofheld taut between the stud 82 and the boss 85 of the distributor arm 74.A new leading end o f the wire 59 is welded to the sleeve 48 of the nextsuccessive pin and sleeve subassembly 42 in the cutting station 170 andextends counterclockwise therefrom as viewed in FIG. 1 to the wiresupply spool 131.

l SWAGING STATION After the wire 59 has been severed from the leadingside of a pin and sleeve subassembly 42 which is held in the workholder63 in the third work station, the workholder currently in the severingstation is indexed with the turntable 61 in a clockwise direction, asviewed in FIG. 2, to move the pin and sleeve subassembly into a fourthwork station and into registration with a swaging device, designatedgenerally by the numeral 190 (see FIG. 16).

lt will be recalled that the pin and sleeve subassembly 42 has beenformed prior to the assembly thereof with the shell and cap subassembly43 in the apparatus 60 and has a somewhat flared peripheral edge on theupper portion of a sleeve 48. The flared peripheral edge of the sleeve48 curves outwardly and must be swaged inwardly to conform generallywith the surface of the cylindrical sleeve.

The swaging device includes a swaging tool, designated generally by thenumeral 191, which is mounted on a bracket 192 which is attached to thetop surface of the top platform 68. The swaging tool 191 is moveddownwardly by an air cylinder 193 attached to a top portion of thebracket to engage the swaging tool and the sleeve 48 of the pin andsleeve subassembly 42. The swaging tool 191 has a die cavity 194 formedin the lower end thereof. The die cavity 194 is concentric with theouter circumference of the sleeve 48 of the pin and sleeve subassembly42. Moreover, the innermost portion of the die cavity 194 is rounded sothat as the swaging tool 191 is moved downwardly over the sleeve 48, thecurved outer rim portion of the sleeve is swaged inwardly by the wall ofthe die cavity.

As the swaging tool 191 is moved over the sleeve 48, currentlypositioned in the fourth work station to swage the rim of the sleeve,the cutting blades 171-171 at the cutting station are moved to severthewire 59 from the supply spool 131. Consequently, at this time, the pinand sleeve subassembly 42 currently in registration with the swagingdevice 190 has a leading bared end of a wire 59 `welded to the topportion of the sleeve 48 and has a predetermined length of insulatedwire 59 extending in a generally counterclockwise direction with atrailing portion thereof held tensioned between the stud 82 and the boss85 of the distributor arm 74.

WIRE WINDING The rack 94 is positioned on the base 62 so that the pinion92 on the shaft 91 of each of the workholders 63-63 engages initiallythe teeth of the rack when th`e workholder is moved out of registrationwith the swaging device 190. After the rim of the sleeve 48 is swaged bythe swaging tool 1 91, the turntable 61 is indexed whereupon the pinion92 engages the rack 94 to rotate the shaft 91 and the chuck 86 (see FIG.18).

As can be observed from FIG. 18, the rack 94 has a lead-in segment 196which is attached to a pivotally mounted bar 197. The bar 197 is biasedin a clockwise direction, as viewed in FIG. 18, by a spring 198 bearingon a lever 199 that is secured to the base plate 62. By thisarrangement, the lead-in segment 196 yields and is moved pivotally in acounterclockwise direction should one of the teeth 96-96 (tooth 96c inFIG. 18) approach the rack segment so as to jam thereagainst. Theyielding motion of the lead-in segment 196 facilitates the meshing ofthe pinion 92 with the rack 94.

The annular cam surface 69 varies from a height slightly above the levelof the platform 68 from the first to the fourth work stations and thento a minimum winding height and back to a maximum winding height hl asthe turntable is indexed from the fourth workv station through a fifthwork station and into a sixth work station at which ones of the mass ofshell and cap subassemblies 43-43 are assembled to successive ones ofthe pin and sleeve subassemblies 42-42.

Moreover, the annular cam surface 69 is configured so that the height h(see FIG. 13) of the cam surface is degreased gradually starting at apoint on the cam surface directly above the point of engagement of thepinion 92 with the rack 94. Subsequently, the cam foli lower 78 ridingon the cam surface 69 is urged upwardly to move pivotally the tensionarm 74 and overcome the spring 79 to raise the trailing end thereofupwardly and distribute the convolutions of the wire 59 on the sleeve 48of the pin and sleeve subassembly 42. In this way the distributor arm 74is moved pivotally first in a clockwise and then in a counterclockwisedirection, as viewed from outside the turntable 6l, to

array two layers of the wire 59 on the sleeve 48 on each of the pin andsleeve subassemblies 42-42.

Also, it will be recalled that a stud 82 in the workholder 63 cooperateswith the boss 85 formed on the one end of the distributor arm 74 to holdthe insulated wire 59 between the stud 82 and the top portion of the arm74. Now, since the trailing end of the wire 59 has been severed, thewinding of the wire 59 on the sleeve 48 of the pin and sleevesubassembly 42 pulls the wire between the stud 82 and the boss 8S of thetension arm 74. In this way, the tension device 81 serves to guide thewire 59 extending from the pin and sleeve assembly 42 as thedistribution of the wire is made on the sleeve 48 of the pin and sleevesubassembly 42.

CONTROL SYSTEM AND OPERATION In describing the operation of theapparatus 60, reference is made to FIG. which shows various limitswitches of an electrical control circuit, designated generally by thenumeral 300, for controlling the operation of the apparatus. Initially,an operator depresses a pushbutton switch (not shown) to initiate thecycle of operation to position one of the pin and sleeve subassemblies42-42 over one of the chucks 86-86 and for opening the chuck, and tooperate a clutch (not shown) to index the apparatus 60.

A photoelectric unit 301 is connected into the circuit 300. Normally,when one of the shell and cap subassemblies 43--43 appear in the lowerportion of the feeding device 210, the light beam associated with thephotoelectric unit 301 is broken. Should a jam-up occur and there is noshell and cap subassembly 43 in the lower portion of the feeding device210, the light beam is unbroken. Then the operator throws a switch (notshown) to complete a circuit through the index motor 67 which iscontinuously running.

The return of all of the stations to an unoperated position at thebeginning of the cycle actuates a plurality of limit switches. Thereturn of the anvil electrodes of the welding devices 150 and 240actuate the limit switches 302 and 303, respectively, while the returnof the welding electrodes thereof operate limit switches 304 and 306,respectively. The return of the cutting blades 171-171 operates a limitlswitch 307, while the return of a blade of the stripping device 200operates a limit switch 308. Moreover, the return of the testing andsorting device 260 operates the limit switch 309 to close the Contactthereof.

When the pin and sleeve subassembly feeding device 100 is returned to anunoperated position, the collet chuck 86 is closed, which completes acircuit (not shown) for the return of the pin and sleeve subassemblyplacement slide 116. Also, the return of the testing and sorting device2 60 to an unoperated position completes a circuit (not shown) andtheturntable 61 is indexed.

After the turntable 61 has been indexed and the index clutch (not shown)disengaged, and if the turntable has been indexed through apredetermined angle of rotation, the workholders 63-63 are preciselyaligned with the work stations and a limit switch 311 is actuated by aspring biased indexing pin (not shown) on the base 62 which is urgedinto one of the plurality of holes (not shown) in the turntable that arealigned with the workholders. Should the turntable 61 not be indexedfully, the pin (not shown) will not engage one of the index holes (notshown) and the limit switch 311 is not actuated.

Provided the turntable 61 has been indexed fully, the limit switch 311is actuated and a circuit is conditioned for the return stroke of theshell and cap feeding device 210.

Also, provided there is a supply of the shell and cap subassemblies43-43 in the shell and cap feeding device 210, the contact of thephotoelectric unit 301 is closed. The depression of the cycle startpush-button switch (not shown) is interlocked to complete a circuit (notshown) to maintain the circuit through the bowl feeder 102.

The air cylinder 126 is actuated to move downwardly the block 128 andopen the collet chuck 86 of the workholder 63 in registration with thefeeding device 100. Finally, a circuit (not, shown) is completed tooperate the air cylinder 117 to advance the slide 116 to position one ofthe pin and sleeve subassemblies 42- 42 over the workholder 63 inregistration with the feeding device 100.

As the collet chuck 86 is opened, and the slide 116 is moved outwardlyover the pin and sleeve subassembly 42 in the leading one of theworkholders 63-63, the arm 120 actuates a limit switch 312 and a limitswitch 313 (see FIGS. 10 and 20) to complete a circuit (not shown) tooperate the air cylinder 122. The operation of the air cylinder 122moves downwardly the insert ram 121 to move the pin and sleevesubassembly 42 through the nest 114 and into the vchuck 86 of theleading one of the workholders 63--63.

As the insert ram 121 is moved downwardly, the insert ram actuates alimit switch 314. The actuation of the limit switch 314 completes acircuit (not shown).

The jaws of the collet chuck 86 are spring returned to a normal closedposition with the pin and sleeve subassembly 42 held therebetween. Asthe collet chuck 86 is closed, the limit switch 316 is actuated to closethe contact thereof and complete a vcircuit to actuate the air cylinder117 and return the pin and sleeve placement slide 116. As the slide 116is withdrawn to the left, as viewed in FIG. 10, the limit switch 313 isactuated to move retractably the insert ram 121.

As the insert ram 121 is returned upwardly, the limit switch 314 isactuated to complete a circuit to condition partially the all stationsreturn circuit (not shown).

It should be observed that after each indexing movement and theoperation of the work tools at the work stations, that the index clutch(not shown) will be engaged to render effective the continuously runningmotor 67 to index the turntable 61` Simultaneously, with the operationof the pin and sleeve subassembly feeding device at the first workstation, the air cylinders 13S-135 are moved downwardly, as viewed inFIG. 12 with'the upper holddown bars 137-137 clamping the wire 59therebetween.

The cylinder 144 is actuated to advance the wire stripping blade 141 tostrip a predetermined length L of the wire 59 which is subsequentlywelded to the sleeve 48 of the pin and sleeve subassembly 42. As theblade 141 is moved upwardly and to the left, as viewed in FIG. 12, bythe rod 143, the cam follower 14S traces the cam opening 146.

An air blast device (not shown) is operated to direct a stream of airagainst the insulation being removed from the wire 59. Should the wire59 be broken during the stripping operation, the tension on the wire 59is released to permit a feeler to actuate a limit switch 318 to completea circuit to illuminate a lamp (not shown) to indicate a broken wire(see FIG. 12).

Moreover, the air cylinder 163 (see FIG. 13) is actuated to advance theanvil velectrode 151 into engagement with the sleeve 48 of the pin andsleeve subassembly 42 which is positioned in the workholder 63 currentlyin registration with the welding device 150. The movement of the anvilelectrode 151 into engagement with the sleeve 48 actuates limit switch321 to close the lcontact thereof and complete a circuit through acounter (not shown) to cycle the welding electrode 152 into engagementvwith the stripped portion of the wire 59 and the sleeve 48 to weld thewire to the sleeve ofthe pin and sleeve subassembly 42.

As the welding electrode 152 is advanced into engagement with the wire59, the welding electrode actuates limit switch 322 to close a contactthereof and complete a circuit for advancing the anvil electrode 151.

To complete the cycle of the welding electrode 152, the weldingelectrode is returned to a normal retracted position. As the weldingelectrode 152 is moved to the left, as viewed in FIG. 13, the weldingelectrode actuates the limit switch 304. The actuation of the limitswitch 304 conditions partially the all stations return circuit (notshown). Then the anvil electrode 151 is returned radially inward and tothe right, as viewed in FIG. 13, and actuates the limit switch 302 toclose the contact thereof to further condition partially the allstations return circuit (not shown).

Simultaneously, with the feeding of a pin and sleeve subassembly 42 inthe first work station and the feeding of the wire 59 and the welding ofa stripped portion thereof to the sleeve 48 of another pin and sleevesubassembly 42 `in registration with the welding device 150, the cuttingdevice 170 is operated to sever the wire 59 at the third work station.Then a length of the wire 59 has a leading end welded to the pin andsleeve subassembly 42 in the fourth work station and the trailing endthereof held taut in the tensioning device 81 of the workholder in thefourth work station with a new leading end of the wire which continuesto the supply spool 131 welded to the pin and sleeve subassembly in thethird work station.

The air cylinder 178 is operated to move the cutting blades 171-171 tosever the wire between the trailing end of one of the workholders 63.*63and the pin and sleeve subassembly 42 in the next successive one of theworkholders.

As the cutting blades 171-171 are advanced toward each other to severthe wire 59, the cutting blade actuates the limit switch 307.Subsequently, the air cylinder 178 is actuated to return the cuttingblades 171-171 to an unoperated condition. As the cutting blades 171-171are returned to an unoperated condition, the limit switch 307 isactuated to condition partially the circuit for the return of allstations for the next cycle of operation. After all stations have beenreturned to an unoperated position, the index clutch (not shown) isengaged and the turntable is indexed through an increment of rotation toadvance each of the workholders 63-63 to the next successive workstation.

Then a leading one of the workholders 63-63 is moved with the turntable6l in a clockwise direction, as viewed in FIG. 2, to position the pinand sleeve subassembly 42 in registration with the swaging device 190.As the air cylinder 178 of the cutting device 170 is actuated to severthe wire 59 at the third work station, the air cylinder 193 of theswaging device 190 is actuated to move the die 194 (see FIG. 16)downwardly and into engagement with the sleeve 48 of the pin and sleevesubassembly 42 in registration therewith. The

' die 194 swages the rim of the sleeve 48 to turn the peripheral edgethereof inwardly. Then, as the cylinder 178 is actuated to return thecutting blades 171-171 at the third work station, the air cylinder 193is actuated to move the die 194 out of engagement with the pin andsleeve subassembly 42 so that the turntable 61 may be indexed.

Then as the turntable 61 is indexed in a clockwise direction, as viewedin FIG. 2, to move the leading one of the workholders 63-63 into thefifth work station, the cam follower 78 on the distributor arm 74follows the lowered contoured configuration of the annular cam surface69 to permit the spring 79 to move pivotally the distributor arm in adownward'direction. Simultaneously therewith, the pinion on the lowerportion of the shaft 91 engages the entrance teeth on the rack 94 (seeFIG. 18) beneath the turntable 6l. As the turntable 61 is indexed, thepinion 92' cooperates with the rack 94 to turn the shaft 91 and hencethe chuck 86 with the pin and sleeve subassembly 42 held therein. Then,as the height of the cam surface 69 increases and as the turntable 61 isindexed to advance the leading one of the workholders into the sixthwork station, the trailing end of the distributor arm 74 is movedupwardly to distribute a second layer of convolutions of the wire 59 onthe sleeve 48 as the pin and sleeve subassembly 42 is rotated with thechuck 86.

It should be observed that while the distribution of the wire 59 is madeon the sleeve 48, the wire extending from the sleeve 48 is tensioned bythe tensioning device 81 at the trailing end of the workholder 63. Asthe pinion 92 disengages from the rack 94 beneath the turntable 6l, thechuck 86 and the pin and sleeve subassembly 42 are no longer rotatedwithin the workholder 63 and, simultaneously therewith, the annular camsurface 69 assumes a level configuration so that the distributor arm 74is no longer moved pivotally but is maintained by the spring 79 in aposition generally somewhat above with the platform 68. At the close ofthe wire distribution cycle, the turntable 61 has been indexed toadvance the pin and sleeve subassembly 42 with the wire 59 distributedon the sleeve 48 thereof into the sixth work station where one of a massof the shell and cap subassemblies 43-43 is assembled to the pin andsleeve subassembly.

At the sixth work station, successive ones of the shell and capsubassemblies 43-43 are fed from a bowl feeder and assembled tosuccessive ones of the pin and sleeve subassemblies 42-42.

The stripping device 200 is advanced to strip a portion of the wire 59near the trailing end thereof. As the stripping device 200 completes apath of motion of, first, into engagement with the wire 59, and thenalong limit switch 308 to return the stripping device to an unoperatedposition.

Also, a bypass circuit is completed to direct a blast of air against thewire to force the stripped insulation material away from the wire 59. K

'At the seventh station, the bared portion of the trailing end of thewirei59 is welded to the cap S9 of the shell and cap subassembly 42 inthe workholder 63.

After the trailing end of the wire 59 has been welded to the cap 56 andthe strength of the weld tested, the pin and sleeve subassembly isindexed to an eighth and final work station where an electricalcharacteristic of the heat coil assembly 41 is determined and where theheat coil assembly is sorted in accordance with the electricalcharacteristic.

As the turntable 6l is indexed to move the workholder 63 currentlypositioned in registration with the testing and sorting station 260toward the pin and sleeve subassembly feed device 100, the chuck 86 ismoved adjacent to, but spaced below a limit switch 333 (see FIG. 20).Should the heat coil assembly 41 not be -removed from the workholder 63at the testing and sorting device 260, the heat coil assembly engagesand actuates the limit switch 333 to complete circuit paths in theelectrical circuit 300 to discontinue operation of the welding device240.

And, finally, as the turntable 61 is indexed to move the workholder 63from the testing and sorting device 260 to the feeding device 100, ascrap wire discarding device 277 engages the tensioning device 81 toforce open the groove therein to permit an air blast fromv a tube 279 todirect the scrap wire away from the workholder.

It is to be understood that the above-described arrangements are simplyillustrative of the principles of the invention. Other arrangements maybe devised by those skilled in the art which will embody the principlesof the invention and fall within the spirit and scope thereof.

What is claimed is:

l. A method of attaching insulated wire from a supply thereof to a partheld in a rotatably mounted workholder having a toothed wheel attachedthereto and for winding the wire on the part as the toothed wheel isadvanced along and in engagement with a rack, which comprises the stepsof:

removing the insulation from a leading portion of the wire;

advancing the workholder into engagement with an orienting device torotate the toothed wheel to orient the toothed wheel so that the toothedwheel is positioned to engage subsequently with the rack;

wind the wire on the part. A method of attaching insulated wire from asupply thereof to a part held in a rotatably mounted workholder having atoothed wheel attached thereto and for winding the wire on the part asthe toothed wheel is advanced along a path of travel and in engagementwith a rack, which comprises the steps of:

removing the insulation from a leading portion of the wire; causingrelative movement between the wire and the part to engage the leadingportion of the wire with the part with the wire running to the supplythereof; securing the bared leading portion of the wire to the part; jmounting the rack adjacent the path of travel to cause the rack toengage the teeth of the toothed wheel as the toothed wheel is advancedalong the path of travel; mounting a teeth engaging surface adjacent thepath of travel ahead of the rack, the teeth engaging surface beinggenerally parallel to the predetermined path of travel and spaced fromthe axis of rotation of the toothed wheel a predetermined distancebetween the distance from the axis of rotation of the toothed wheel andthe root of the teeth thereon and the distance between the axis ofrotation of the toothed wheel and the crest of the teeth thereon so thatas the toothed wheel is advanced along the p'ath of travel the toothedwheel engages the surface and is oriented properly with respect to therack prior to engagement of the toothed wheel with the rack; advancingthe workholder along the path of travel to first engage the toothedwheel with the teeth engaging surface to orient the toothed wheel; andfurther advancing the workholder along the path of travel to engage thetoothed wheel with the rack and to then roll the toothedwheel along therack to move rotatably the workholder while tensioning the wire to windthe wire on the part.

1. A method of attaching insulated wire from a supply thereof to a partheld in a rotatably mounted workholder having a toothed wheel attachedthereto and for winding the wire on the part as the toothed wheel isadvanced along and in engagement with a rack, which comprises the stepsof: removing the insulation from a leading portion of the wire;advancing the workholder into engagement with an orienting device torotate the toothed wheel to orient the toothed wheel so that the toothedwheel is positioned to engage subsequently with the rack; causingrelative movement between the wire and the part to engage the leadingportion of the wire with the part with the wire running to the supplythereof; securing the bared leading portion of the wire to the part;advancing the workholder to engage the toothed wheel with the rack, andfurther advancing the workholder to roll the toothed wheel along therack to move rotatably the workholder while simultaneously tensioningthe wire to wind the wire on the part.
 2. A method of attachinginsulated wire from a supply thereof to a part held in a rotatablymounted workholder having a toothed wheel attached thereto and forwinding the wire on the part as the toothed wheel is advanced along apath of travel and in engagement with a rack, which comprises the stepsof: removing the insulation from a leading portion of the wire; causingrelative movement between the wire and the part to engage the leadingportion of the wire with the part with the wire running to the supplythereof; securing the bared leading portion of the wire to the part;mounting the rack adjacent the path of travel to cause the rack toengage the teeth of the toothed wheel as the toothed wheel is advancedalong the path of travel; mounting a teeth engaging surface adjacent thepath of travel ahead of the rack, the teeth engaging surface beinggenerally parallel to the predetermined path of travel and spaced fromthe axis of rotation of the toothed wheel a predetermined distancebetween the distance from the axis of rotation of the toothed wheel andthe root of the teeth thereon and the distance between the axis ofrotation of the toothed wheel and the crest of the teeth thereon so thatas the toothed wheel is advanced along the path of travel the toothedwheel engages the surface and is oriented properly with respect to therack prior to engagement of the toothed wheel with the rack; advancingthe workholder along the path of travel to first engage the toothedwheel with the teeth engaging surface to orient the toothed wheel; andfurther advancing the workholder along the path of travel to engage thetoothed wheel with the rack and to then roll the toothed wheel along therack to move rotatably the workholder while tensioning the wire to windthe wire on the part.